CN110116265B - Heterogeneous laminated plate single-point numerical control connection and progressive composite forming system and application thereof - Google Patents
Heterogeneous laminated plate single-point numerical control connection and progressive composite forming system and application thereof Download PDFInfo
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- CN110116265B CN110116265B CN201910339288.8A CN201910339288A CN110116265B CN 110116265 B CN110116265 B CN 110116265B CN 201910339288 A CN201910339288 A CN 201910339288A CN 110116265 B CN110116265 B CN 110116265B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D37/00—Tools as parts of machines covered by this subclass
- B21D37/16—Heating or cooling
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
- B23K20/12—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding
- B23K20/122—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding using a non-consumable tool, e.g. friction stir welding
- B23K20/1275—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding using a non-consumable tool, e.g. friction stir welding involving metallurgical change
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
- B23K20/24—Preliminary treatment
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Abstract
The invention relates to a heterogeneous laminated plate single-point numerical control connection and progressive composite forming system and application thereof. Compared with the prior art, the invention does not need to carry out pre-connection of laminated plates and additional manufacturing dies, can realize synchronous connection forming of heterogeneous plates, overcomes the defects of poor synchronous connection forming capability, low processing efficiency and the like of heterogeneous metal materials, and combines the advantages of pressure friction welding and incremental forming.
Description
Technical Field
The invention relates to a metal plate plastic forming technology in the field of mechanical manufacturing and processing, in particular to a heterogeneous laminated plate single-point numerical control connection and progressive composite forming system and application thereof.
Background
The metal plate incremental forming technology is a flexible manufacturing process means in the field of plastic forming research, can quickly realize a shape customized by a user, has obvious advantages in processing cost compared with the traditional mold development, and is particularly suitable for single-piece or small-batch production. At present, the progressive forming process and theory are deeply researched, and the progressive forming process and theory are mainly applied to forming of steel plates or aluminum alloy plates with good plasticity in practice. The composite metal laminated plate can overcome the defects that a single-layer plate has single performance, and local necking and even breakage often occur due to serious thickness reduction after processing. The traditional processing mode is that the composite board is prepared by specific technological means such as friction stir welding, explosive welding, flat roll rolling, hot-pressing diffusion welding and the like, and then the prepared composite board is used as a part required by raw material production. The multi-procedure production process has high cost, large energy consumption and low efficiency, and is contrary to the realization of a high-end manufacturing concept. Although the mechanism of the aforesaid composite method is not exactly the same, it is essential to achieve connection between metal layers by thermal effect.
The research on the connection and progressive forming of the heterogeneous metal laminated plates is taken as a hot topic of plate forming, and the research is widely researched at home and abroad in recent years, so that the processing technology of target parts under different service working conditions is advanced to a certain extent. Thereby promoting the application prospect of the plate composite manufacturing process and accelerating the mature technology.
The invention patent CN104438480 applied by the inventor of Charlie et al can be found by combining the published patent results, and discloses a sheet material tailor-welding-based incremental forming method, which can connect sheet materials with different thicknesses along the transverse tailor-welding, fully play the incremental forming performance of tailor-welded plates and effectively make up the defect of insufficient plate thickness caused by serious thinning in the incremental forming process; the invention patent CN104607523 of Lubin et al discloses a plate stirring progressive composite forming device and method, which can realize the integration of stirring friction welding and progressive forming after the thick-direction lamination of functional gradient materials.
In the device and the method, the device mainly aims at splicing single-layer plates by utilizing the step division and then carrying out incremental forming. The main defects of the method are that the two step-by-step procedures of connection and progressive forming reduce the production efficiency, the manufacturing cost is high, and the method is difficult to directly install and realize the synchronous procedure on the existing progressive forming equipment. The latter composite progressive forming device and method based on the friction stir welding method can realize synchronous forming, but need to design a specific progressive tool head with a stirring pin and a back pressure back-ejection tool head. The thickness of the material at the track where the needle passes during the friction connection is seriously reduced, the surface quality of the sheet formed by the friction stir connection has obvious defects, the synchronous stability of the operation of the double-point equipment is poor, the mechanism design is complex, and the improvement is needed. At present, no systematic feasible method has been developed for the heterogeneous laminate single-point synchronous connection and progressive composite process.
Disclosure of Invention
The invention aims to overcome the defects of the prior art and provide a heterogeneous laminated plate single-point numerical control connection and progressive composite forming system and a method for processing and forming the heterogeneous laminated plate by using the system.
The purpose of the invention can be realized by the following technical scheme:
a heterogeneous laminated plate single-point numerical control connection and progressive composite forming system comprises a clamp, a tool head, a main shaft servo motor and a driving control unit,
the clamps are clamped at the two ends of the heterogeneous laminated plate,
the tool head is in contact with a surface of a heterogeneous laminate,
the main shaft servo motor is connected with the tool head, and the tool head is controlled by the driving control unit to process the heterogeneous laminated plate.
The tool head is of a revolving body flat bottom round corner type structure, the front end face is a flat face, the edge of the end portion is of a round corner structure, the flat bottom portion of the tool head plays a role in pressing and rubbing to generate heat transfer for connecting heterogeneous laminated plates, and the round corner portion of the tool head is used for applying forming force.
The diameter of the cross section of the tool head is 20-40mm, and the contact area between the flat surface of the end part of the tool head and the plate is 75-80% of the area of the cross section of the tool head.
The tool head is made of wear-resistant and high-temperature-resistant tungsten carbide hard alloy through machining.
The application of the heterogeneous laminated plate single-point numerical control connection and progressive composite forming system comprises the following methods:
preprocessing a heterogeneous laminated plate, and clamping and fixing the heterogeneous laminated plate on a workbench by using a clamp;
calibrating the lower cutter position and the initial height of the tool head, transmitting corresponding NC codes into the drive control unit, and driving a main shaft servo motor by using the drive control unit, wherein the servo motor controls the motion track of the tool head;
processing the tool head according to the motion track and the motion time;
and checking the forming profile precision and the connection strength of the machined part to finish the forming of the heterogeneous laminated plate.
The upper two layers of the laminated plate are plate materials of a piece to be formed, and the lowest layer of the laminated plate is an auxiliary plate. Through friction of a tool head and heat generation caused by deformation of a plate, the temperature of a contact interface of the plate of the composite layer continuously rises, metallurgical connection of an intermetallic compound layer with a certain thickness is generated in a local deformation zone, and synchronous deformation is completed under the action of coupled thermal cycle. An auxiliary plate coated with a boron nitride blocking agent on the surface is arranged below the composite layer, so that the interface connection condition and the outline precision of a formed part can be effectively improved. The auxiliary plate provides a back reaction force, so that the shape accuracy of a formed part can be ensured during incremental forming, and the connection characteristic between the base material plates can be improved.
The heterogeneous laminated plate needs surface pretreatment, and the contact surfaces of two layers of plate materials are uniformly polished by an electric brush until fresh surfaces are exposed so as to remove an oxide layer on the surface of the rolling plate. And uniformly coating a boron nitride blocking agent with the thickness of 0.1-0.2mm on the upper surface of the auxiliary plate. In order to ensure good mechanical properties, the rolling direction of the plane of the three-layer plate is kept consistent when the three-layer plate is stacked and clamped.
The tool head completes the progressive forming of the workpiece outline along a preset CAD track and is controlled by a CNC machining center. The technological window parameters include 3000 plus 6000rpm, lamination height of 0.1-0.3mm and machining depth not lower than 20 mm.
And cutting chips generated by the surface contact of the plate are removed in time in the machining process.
The invention finally realizes the connection of two heterogeneous plates by utilizing a pressure friction heat generation mode. The invention can realize the synchronous connection forming of heterogeneous plates and overcome the defects of poor synchronous connection forming capability, low processing efficiency and the like of heterogeneous metal materials. And the characteristics of the tool head can be actively adjusted according to the requirements and equipment conditions, the pre-connection of laminated plates and an additional manufacturing mould are not needed, and the advantages of pressure friction welding and incremental forming are combined. Compared with the prior art, the invention has the following beneficial effects:
1) the heat production quantity is adjusted by directly controlling friction and deformation conditions in a process window by using process parameters such as feed ratio, rotating speed and the like, so that the connection and the forming of two heterogeneous plates are realized. The method can overcome the problems of poor connecting and forming capabilities of heterogeneous metal materials, unsynchronized connecting and incremental forming processing and the like. An excessively strong process parameter combination exceeding a proper process window can cause the temperature rise to be excessively fast, the material flow of the upper surface contacted with the tool head is accelerated, the cutting effect is obviously enhanced, and brittle intermetallic compounds between heterogeneous plates are rapidly and unevenly generated, so that the surface quality and the connection strength of a final formed part are not met; a weaker process parameter combination, less than the proper process window, will result in insufficient temperatures for rubbing and deformation to produce a solid state connection between the foreign plates.
2) By adopting the existing single-point CNC (computerized numerical control) machining center, the size and the motion track of the tool head can be adjusted according to the characteristics of a formed piece so as to obtain the machining track suitable for different workpieces. The laminated plates do not need to be connected in advance, the process steps are reduced, and the advantages of pressure friction welding and incremental forming are combined.
3) The method does not need to arrange a groove or a stirring pin on a tool head, and can ensure good temperature rise effect by combining two major heat generating methods of material plastic deformation and surface friction, reduce manufacturing procedures and cost and improve the surface quality of a formed part. The diameter of the cross section of the tool head is 20-40mm, the contact area of the flat surface of the end part and the plate is 75% -80% of the cross section area of the round rod of the tool head, and the compactness of the contact surface, the sufficient heat generation area and the surface quality of a formed part during the rotation friction of the tool head are guaranteed. An excessively large tool head will reduce the formability of the progressive forming; and an excessively small diameter of the cross section results in a reduction in the frictional contact area, suppressing the heat generation effect.
4) The fillet radius of the tool head fillet structure is at least 2 times of the sum of the thicknesses of the three plates, so that the movement resistance in the forming process can be effectively reduced, and the surface of a material is prevented from being scratched.
5) The auxiliary plate is required to have certain strength and plasticity and can provide enough supporting force for incremental forming. The thickness of the boron nitride barrier coating on the upper surface of the auxiliary plate in contact with the shaped piece is about 0.1-0.2mm to ensure that the auxiliary plate does not connect with the heterogeneous laminate.
Drawings
FIG. 1 is a schematic diagram of a heterogeneous laminate single point NC connection and progressive composite forming system;
fig. 2 is a partial schematic view of the tool head moving along a contour machining path on a machining plane.
In the figure, 1-auxiliary plate, 2-plate, 3-plate, 4-clamp, 5-tool head, 6-drive control unit, 7-main shaft servo motor and 8-local forming track.
Detailed Description
The present invention will be described in detail with reference to specific examples. The following examples will assist those skilled in the art in further understanding the invention, but are not intended to limit the invention in any way. It should be noted that variations and modifications can be made by persons skilled in the art without departing from the spirit of the invention. All falling within the scope of the present invention.
Examples
The structure of the heterogeneous laminated plate single-point numerical control connection and progressive composite forming system is shown in figure 1, and the heterogeneous laminated plate single-point numerical control connection and progressive composite forming system comprises a clamp 4 for clamping two layers of heterogeneous plates 2 and 3 to be formed and an auxiliary plate 1, a tool head 5 for forming by contacting with the surface of a heterogeneous metal plate, and a main shaft servo motor 7 and a driving control unit 6 of the tool head; the tool head 5 rotates at a high speed to contact with the plate and feeds along the circumferential direction, and generates intermetallic compound metallurgical connection under the combined action of friction heat generation and pressure coupling circulation in a mode of transferring to the interface heating of the composite layer, so that the synchronous connection and deformation of the composite layer are completed. Wherein the drive control unit 6 may implement force control or displacement control of the tool head 5. The plate 2, the plate 3 and the auxiliary plate 1 to be formed are flatly clamped on the workbench through a clamp 4. The drive control unit 6 is connected with the tool head 5 through a spindle servo motor 7, and the drive control unit 6 drives the tool head to move in translation and rotation in X, Y, Z space coordinate system, wherein the rotation direction of the tool head 5 can be positive or negative. Fig. 2 shows a schematic view of a local contour-type trajectory of the tool head 5, which is stepped in the circumferential direction and the radial direction along the contour of the piece to be formed on the machining plane, forming a local forming trajectory 8.
The tool head 5 has 4 degrees of freedom of movement, including 3 coordinate axis translational degrees of freedom and 1 rotational degree of freedom. The material is tungsten carbide hard alloy to ensure high melting point and high hardness.
The composite synchronous forming method comprises the following implementation steps:
step S1: pretreating laminated plate
Removing oxide layers on the surfaces of the plate 2 and the plate 3 by using an electric brush, uniformly polishing until fresh surfaces are exposed, uniformly coating a boron nitride blocking agent with the thickness of 0.1-0.2mm on the upper surface of the auxiliary plate 1, clamping and fixing the processed base material and the auxiliary plate on a clamp 4 according to the same rolling sequence, and keeping the rolling directions of the planes of the three layers of plates consistent when stacking and clamping;
step S2: tool setting and machining program selection
Determining the motion track and the motion time of the tool head 5 according to the shape of a forming part, transmitting a corresponding written NC code into a driving control unit 6, and calibrating the cutting position and the initial height of the tool head for the cutter;
step S3: machining and removing cutting chips
According to the single-point progressive forming processing track loaded by the computer processing main program, the process window parameters comprise the rotating speed of 3000 plus 6000rpm, the layer-entering height of 0.1-0.3mm and the processing depth of not less than 20mm, two plates are subjected to medium-high speed rotating pressure friction heating by a tool head to complete the connection of heterogeneous metal plates, and meanwhile, the progressive forming is carried out based on the preset processing track. And cutting chips possibly generated when the tool head is contacted with the surface of the plate material are removed in time, so that the surface quality of the machined part is ensured. In the process of incremental forming, for each section of processing track, the program sets the tool head to carry out incremental forming according to the processing track, and the auxiliary plate 1 serves as a back plate to provide supporting counter force. The process parameters can be adjusted according to specific materials and forming conditions in the step, so that different frictional heat inputs can be realized.
Step S4: taking out and checking the quality of the formed part
After the preset processing is finished, the tool head returns to the position of the program set 0 point, the workpiece clamp is loosened, the auxiliary plate (1) is removed after the forming piece is taken down, and the forming profile precision and the connection strength of the laminated plate are verified.
The embodiments described above are described to facilitate an understanding and use of the invention by those skilled in the art. It will be readily apparent to those skilled in the art that various modifications to these embodiments may be made, and the generic principles described herein may be applied to other embodiments without the use of the inventive faculty. Therefore, the present invention is not limited to the above embodiments, and those skilled in the art should make improvements and modifications within the scope of the present invention based on the disclosure of the present invention.
Claims (10)
1. A heterogeneous laminated plate single-point numerical control connection and progressive composite forming system is characterized by comprising a clamp, a tool head, a main shaft servo motor and a driving control unit,
the clamps are clamped at the two ends of the heterogeneous laminated plate,
the tool head is in contact with a surface of a heterogeneous laminate,
the main shaft servo motor is connected with the tool head, and the tool head is controlled by the driving control unit to process the heterogeneous laminated plate;
an auxiliary plate is arranged below the heterogeneous laminated plate and clamped in the clamp, and the upper surface of the auxiliary plate is uniformly coated with a boron nitride blocking agent with the thickness of 0.1-0.2 mm.
2. The heterogeneous laminate single-point numerical control joining and incremental forming system of claim 1, wherein the tool head is a flat-bottom rounded corner structure of a solid of revolution, the front face is a flat face, and the edges of the flat face are rounded corners.
3. The heterogeneous laminate single-point numerical control connecting and incremental forming system of claim 2, wherein the contact area between the flat surface of the tool head end and the heterogeneous laminate is 75-80% of the cross-sectional area of the tool head, and the fillet structure has a fillet radius at least 2 times the sum of the thicknesses of the three heterogeneous laminates.
4. The heterogeneous laminate single point, digitally controlled connection and incremental forming system of claim 1, wherein the tool head is machined from a wear and high temperature resistant cemented tungsten carbide.
5. Use of a heterogeneous laminate single point numerically controlled joining and progressive composite forming system as claimed in claim 1, comprising the following method:
preprocessing a heterogeneous laminated plate, and clamping and fixing the heterogeneous laminated plate on a workbench by using a clamp;
calibrating the lower cutter position and the initial height of the tool head, and driving a main shaft servo motor by using a driving control unit, wherein the servo motor controls the motion track of the tool head;
processing the tool head according to the motion track and the motion time;
and checking the forming profile precision and the connection strength of the machined part to finish the forming of the heterogeneous laminated plate.
6. Use of a heterogeneous laminate single point NC joining and progressive composite forming system according to claim 5, wherein an auxiliary plate is further provided under the heterogeneous laminate, clamped in the jig.
7. The use of the heterogeneous laminate single-point NC connecting and incremental forming system according to claim 6, wherein the heterogeneous laminate is uniformly ground to expose a fresh surface by an electric brush to remove an oxide layer on the surface of the rolling plate, and a boron nitride barrier agent with a thickness of 0.1-0.2mm is uniformly coated on the upper surface of the auxiliary plate.
8. Use of a heterogeneous laminate single point numerically controlled connection and progressive composite forming system according to claim 6, wherein the rolling directions of the planes of the heterogeneous laminate and the auxiliary plate are kept in line during the stacking and clamping.
9. The use of the heterogeneous laminate single-point NC connecting and incremental forming system of claim 5, wherein the tool head performs incremental forming of the profile of the workpiece along a predetermined CAD trajectory, the tool head is controlled by a CNC machining center, the rotation speed during machining is controlled to 3000-6000rpm, the step height is 0.1-0.3mm, and the machining depth is not less than 20 mm.
10. The use of a heterogeneous laminate single point NC joining and incremental composite forming system as claimed in claim 5, wherein the cutting chips generated by the contact of the sheet surfaces are removed in time during the process.
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| CN112845832B (en) * | 2021-01-08 | 2022-05-27 | 上海交通大学 | Progressive forming method of sheet metal part with non-cavity geometric characteristics |
| CN114939714B (en) * | 2022-06-08 | 2023-05-16 | 南昌航空大学 | Electromagnetic pulse assisted friction stir lock welding processing device and method |
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| CN101318203A (en) * | 2008-06-24 | 2008-12-10 | 南京航空航天大学 | Electrical heating numerical control incremental forming processing method and device for plate |
| CN102303072A (en) * | 2011-05-18 | 2012-01-04 | 扬州大学 | Plate material evolutionary impact forming process method |
| KR20160077719A (en) * | 2014-12-24 | 2016-07-04 | 경북대학교 산학협력단 | Incremental sheet forming apparatus and incremental sheet forming method |
| CN104607523B (en) * | 2015-02-13 | 2017-03-15 | 上海交通大学 | A kind of plate stirs progressive compound molding device and method |
| CN109249118B (en) * | 2018-08-21 | 2020-03-17 | 上海交通大学 | Laminated plate synchronous composite double-point progressive forming device and method based on resistance welding |
| CN109277468B (en) * | 2018-08-21 | 2019-09-27 | 上海交通大学 | A kind of laminated plate synchronized links and progressive Composite forming tool and method |
| CN109622755B (en) * | 2018-12-21 | 2020-06-02 | 上海交通大学 | Composite forming device and method for heterogeneous metal plate raw materials |
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